Gears LLC 105 Webster St. Hanover Massachusetts 02339 Tel.

781 878 1512 Fax 781 878 6708 www.gearseds.com

Identify and Assemble the Pneumatic Components

The 5 Basic Components

The Standard GEARS-IDS™ Pneumatic system
is comprised of 5 components.

The Reservoir Stores Potential Energy in the

form of compressed air.
The Shut Off/Purge Valve Isolates the stored air
from the working components in the pneumatic
circuit. This valve depressurizes or vents the
circuit when it is closed.
Regulator Maintains a set pressure in the circuit.
Solenoid Electronically controls the flow of air to
the pneumatic cylinder.
Pneumatic Cylinder Converts the pressurized air
into the mechanical energy of a linear rod and
piston.

The Reservoir
The reservoir is a stainless steel cylinder capped
by two aluminum mounting plates. The
aluminum end plates are each fitted with a 1/8”
NPT threaded port.

A Schrader Valve fitting (Used to fill a bicycle tire) is threaded into one port and used to fill the
cylinder. The other port is fitted with a one touch quick connect fitting that is used as the supply
port for the pneumatic circuit.

To ensure an airtight seal, the threaded ends of the “Quick Connect” fitting and the Schrader
valve are wrapped in Teflon tape prior to being threaded into the reservoir. These fittings are
tightened firmly into the aluminum end caps using a 7/16” box end wrench.
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 3 Way Shut Off Valve
This three position valve is positioned between the
reservoir and the remainder of the pneumatic circuit.

Position One
When the valve knob is aligned perpendicular to the
air flow, (as pictured on the right) the valve will not
pass air to the remainder of the circuit. The valve is
closed.

Position Two
When the knob is aligned with the flow of air (turned
90 degrees from the closed position) the valve passes
air to the circuit and is said to be open.

Position Three
As the valve is turned from the open to the closed
position, the valve will vent downstream circuit
pressure. This helps to ensures that components
downstream of the valve are deactivated.

Note: This is a directional component. The

direction of airflow through the shut off valve is
designated by an arrow on the body of the valve.

The Regulator
The Regulator is fitted with a mounting bracket, a
mounting bracket retaining nut, a 0-1Mpa gauge
and two M5 x 4 MM One Touch fittings. The
gauge is made airtight by sealing the gauge threads
with a drop of red Loctite™ and tightening firmly
by hand.

Note: The M5 x 4MM One Touch Fittings are sealed using (black) gasket sealing rings. If these rings are lost or
missing the fitting will not be airtight. The M5 x 4 MM One Touch fittings can be tightened using a 5/16” box end
wrench

Caution: USE MINIMAL FORCE to tighten these fittings. Fittings damaged by over tightening will not be covered
under warrantee.
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Gears LLC 105 Webster St. Hanover Massachusetts 02339 Tel. 781 878 1512 Fax 781 878 6708 www.gearseds.com
 Note: The regulator is a directional component. Please note the orientation of the directional arrow on the body
of the regulator. Align this arrow in the direction of the airflow. The arrow should point towards the component
immediately downstream of the regulator.

Adjusting Regulator Pressure

Note: The pressure gauge has been removed for clarity.
Pressure downstream of the regulator can be adjusted
using the black plastic knob on the rear of the
regulator. Turning the knob clockwise increases the
force acting on the regulator spring and diaphragm, and
raises the regulated pressure. Turning the knob counter
clockwise reduces the force on the diaphragm and
lowers the regulated pressure.
Direction Arrow
Note: The regulator setting can be “Locked” by
pressing in on the regulator adjustment knob.
Conversely, if the knob does not turn easily it may be
in the locked position. To free the adjustment knob, pull the adjustment knob firmly outward from the body of the
regulator.

The Solenoid Valve

“P” or “1” Port The solenoid valve used in the GEARS - IDS™
Invention and Design System is an electrically
operated on/off air control valve. This valve is a 3/2
valve, having 3 ports
(In, out and exhaust), and two positions (Open,
closed).

The valve is operated with 12 volt DC power provided

from either a hand operated switch or a radio
controlled switch available as an optional electrical
“A” or “2” Port
accessory.

Note: This is a directional component. Airflow through this component enters the through the one touch
fitting threaded into the port marked with either a “P” or a “1” or both. “P” denotes the pressure port. The linear
actuator is connected to the port marked either “A” or “2” or both.

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Gears LLC 105 Webster St. Hanover Massachusetts 02339 Tel. 781 878 1512 Fax 781 878 6708 www.gearseds.com
Linear Actuator or Pneumatic Cylinder
The linear actuator, or pneumatic cylinder is the prime mover in the GEARS - IDS™ pneumatic system.

The linear actuator uses the pressurized air in the system to perform useful work. Air pressure within the cylinder
acts on a 16 MM diameter piston that is connected to the interior end of the rod. The force produced at the piston and
transmitted to the rod and rod clevis is a function of the air pressure entering the cylinder. The air pressure in the
system is controlled by the regulator setting.
The rod clevis can be connected to a variety
of levers and mechanisms and used to
increase either the speed of force of a moving
component.

The linear actuator is fitted with a metered in

flow valve which controls the rate at which
pressurized air enters the cylinder. This in
turn controls the speed with which the rod
extends. This linear actuator is a single acting
cylinder which uses air pressure to extend the
rod and an internal spring to return the rod.

The “One Touch” Fittings

One Touch Fittings allow rapid and repeated
assembly and disassembly of pneumatic
circuits.

When connecting tubing with one touch

fittings, please use the procedure outlined
below.

1. 1. Cut the end of the tubing square. Use

2. cable cutters or a razor knife.

3. 2. Fully depress the outer barrel of the

4. one touch fitting.

3. With the outer barrel held depressed,

insert the tubing until it bottoms out
inside the fitting. Release the barrel.

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Gears LLC 105 Webster St. Hanover Massachusetts 02339 Tel. 781 878 1512 Fax 781 878 6708 www.gearseds.com
 The Connection Sequence
Connect the 5 components using the 4 MM tubing
supplied with the GEARS - IDS™ pneumatic kit.
Connect the components in the order and
arrangement illustrated in the graphic on the right.

Note: Always confirm the direction of airflow

through the component BEFORE attaching the
tubing.

Pressurizing the system is as easy as filling a bicycle

tire. Connect the bicycle pump hose to the Schrader
valve on the reservoir. Lock the pump fitting to the
Schrader valve and pressurize the tank with the
pump.

CAUTION: DO NOT PRESSURIZE THE SYSTEM WITH ANYTHING OTHER THAN A BICYCLE
PUMP. DO NOT EXCEED 145 PSI.

Gears LLC 105 Webster St. Hanover Massachusetts 02339 Tel. 781 878 1512 Fax 781 878 6708 www.gearseds.com5